Water softening apparatus



July 30, 1940. R. E. WAGNER WATER soFTENING APPARATUS Filed Jan. 25, 1957 1, #SAN H un INVENTOR. Q j] ,d if Wagner f El 27 ATR/s.

PATENT OFFICE A WAT APPARATUS wnengorrestllills. Long Island,

im, sex-m No. 121,971 nomma, (ci. sla-s4) 11i-venues to a method c: and ap scttening'water and has for an obpuratusfor-v iectjtheprovlsion in'uirufvements in this art. 'Ihemcst commcnmethod-iordetennining the fase-ranasriwatefa beure son 'soap I vcausesno'cloudines when -a drop isputin soft .but does when putfinliard.water.'v 'Ihis test is used todetermine when'al wollte-softener is exhausted when thezeolite has Inpractice it is usual, afterthef-character of agiven supply of waterhasionce been determined, to regenerate the zeolite `after a predetermined quantity-of water has passed therethrough. This may be done either manually or automatically. This-method, it will be realized, is entirely empirical and does notfurnish an accurate qualitative control of the softness of the water delivered. n A

l I have found that there is sumcient change i'n the pH value ofthe waterduring the cycle of operation of a zeolite softener to permit the use of the pH of the water to determine when a zeolite softener is exhausted, when it is complete- Il ly regenerated and also to give an indication of the softener at, various stages of the cycle of operation. The pH value is dened as the logarithm of the reciprocal of the hydrogen-ion concentration, hence it is a measure of only the I0 hydrogen-ion concentration of a solution. In contrast to this, electrical conductivity is a measure of the concentration o! all ions in the solution, both positive and negative, and which in a water softener eiliuent such as that. under s consideration might include sodium (Na+), potassium (K+), lithium (Li+), calcium (Cai), hydrogen (H+), hydroxyl (OH-L chlorine (C1), normal carbonates (Cor), etc.

Something of the theory of pH measurements 'w and their distinction from conductivity measurements is given in the textbook of W. Manseld Clark, Delamar Professor of Physiological Chemistry at Johns Hopkins University The Determination of Hydrogen Ions 1928. A cona stant reading pH indicator can be used to give a continuous visible reading of the condition of the zeolite and can be used in place of the customary soap test to determine when a zeolite softener is exhausted and also when the regenera- 50 tion is completed. A pH indicator can also be used to automatically control the operation of a zeolite water softener.

In general, the pH value of the eflluent of a zeolite water softener when fully regenerated is higher than that of the untreated water. As

I requires regeneration. Therefore, by testing the pH value of the eiiluent the point of exhaustion oi the zeolite of the softener can readily be determined. There are available on the market pH l0 indicators which are sensitive enough for the present purposes. Some of these indicators read `directly in'pH values. For example, an antimony-calomel electrode assembly and an automatic recorder and controller such as are shown l on page 7 of the Leeds & Northrup Company Bulletin N 96S-744A.1937, may be used.

The antimony-calomel electrode assembly may comprise an antimonyA measuring electrode or half-cell, such as that described on page 13 of 20 the Leeds 8; Northrup Company catalog EN-96- 1937, and a, calomel reference electrode or halfcell such as that described and shown on the left of the illustration on page 14 of this catalog. 'I'he calomel reference electrode is commonly used 25 with any of several different types of measuring electrodes, such as the glass electrode (shown in the illustration on page 14), a hydrogen gas electrode, a. quinhydrone electrode, etc., as described in the catalog. I have found that the antimony measuring electrode is suitable for the purposes of this invention and is desirable because it is simple and rugged. 'Ihe relative positions of the reference (left on page 14 of catalog) and meas- V'uring (right) electrodes are shown in the central 35 portion of Athe illustration on page 14 of the catalog. There they are placed in a sample beaker of test liquid, whereas for a continuous indicator they are placed in a. flowing body of test iiuid, the latter being the type of installation 40 which has been converted and adapted to the purposes of the present invention.

By placing suitable contacts on -the indicator and making connections with suitable controls, the pH indicator may be made to furnish automatic control of the softener in much the same manner as household heating furnaces are controlled from thermostats. Also by a reading of the indicator it can be determined when the softener is exhausted, when completely regenerated. and its condition at any given time.

In the same manner the completion of the removal of brine from the zeolite, i. e., the brine rinsing operation, can be indicated or controlled by the pH value of the eilluent. At the start of the brining operation, and especially as the first brine appears in the eflluent, the pH value of the eflluent will be at approximately its lowestl point. From this point it will gradually rise as the regeneration continues until at the end of the treat-I ment the brine rinse eilluent will have approximately the same pH value as the untreated water or rinse water being fed to the softener, or even higher, indicating completion of regeneration.

By suitable contacts on the pH indicator this high point can be employed to control the brine rinsing operation of the softener; just as the low point of exhaustion is used to start the regeneration.

In order to illustrate the principles of the invention one form of apparatus embodying the invention will now be described in connection with the accompanying drawing in which:

Fig. 1 is a schematic view of a water softener installation; and

Fig. 2 is a sectional view of a pH indicating electrode assembly, such as one of the two indicated diagrammatically in Fig. 1.

Referring to the drawing, the numeral II) indicates a tank containing zeolite water softening material to which hard water to be softened is supplied by pipe I I and from which softened wa-A ter is delivered to pipe I2.`

In order to stop the normal ow of water when thel zeolite in the softener is to be regenerated, the delivery and supply pipes I2 and Il are supplied with solenoid operated valves A and B respectively. The valves are normally open but are closed when electric current flows through the coils of the solenoids.

Recovered brine from the previous regeneration is fed from a brine recovery tank Il through a pipe I5 provided with a check valve I6. As long as pressure is maintained against the lower side of the check valve I6 it cannot open to let the brine flow down but when the back pressure is relieved the valve is permitted to open and the brine to ow into the softener.

The liquid level in tank I4 may be controlled by a float controlled cut-olf valve I1. This valve may be similar to common flush tank valves except that loose motion is provided between the float and the valve operating lever to accommodate for the large capacity of the tank. The valve lever also controls switches S3 and S4, the switch S3 being closed when the iioat is up and being opened when the float is down. 'I'he switch SI is open when the float is up and closed when the float is down. 'I'he valve and related parts are so balanced that the valve and switches are only Aoperated as desired at each end of the float travel. The tank I4 is lled by a supply pipe I8 leading to an outlet pipe I9 connected to the bottom4 of the softener tank I0.

'Ihe outlet pipe I9v connects with a waste pipe 2l. The waste pipe is normally closed by a solenoid valve C but the valve is opened when electric current flows in its solenoid coil from the switch S3.

Means are provided for supplying fresh brine to the top of the softener. This comprises a pipe 22 connected to the pipe I5 below the check valve I6. A pump Pl driven by a motor MI takes brine from a brine measuring tank 23 by way of a pipe 24 and forces it through the pipe 22. The motor MI is controlled jointly by the switch Sl and a switch S5 controlled by a float in the brine measuring tank 23. The switch S5 is closed when the float is up and open when the oat is down.

The float for switch S5 also controls another switch S6 of a solenoid valve D disposed in a hard water by-pass pipe 25 arranged between the hard water inlet pipe II and the brine inlet pipe 22. The valve D is normally closed but is opened when current flows in its solenoid coil from the switch S6.

Means are provided for replenishing the brine in the brine measuring tank 23, this means comprising a pump P2 actuated by .a motor M2 and pipes 26 and 21 taking brine from a brine storage tank 28. A float controlled switch S'I controls the operation of the pump motor M2. The switch is closed when the float is down and opened when the float is in its top position.

The operation of the apparatus may be controlled in any desired manner, either manually by reference to a pH indicator 30 or automatically by the pH indicator. The needle position of this indicator is controlled by a coil 3| responsive. selectively to the pH potential at an electrode assembly 32 in the soft Water line I2 and an elec trode assembly 33 in the brine supply line I8. The electrode assemblies 32 and l33 are not the common type used to measure electrolytic conductivity but are the special type of electrodes suitable for determining pH vales. There is no direct relationship between pH and conductivity. In zeolite water softening operations there is merely an exchange of a soft salt for a hard salt with little or no change in conductivity; but there is considerable change in pH values which apparently has not heretofore been realized and usefully applied. The discovery of this fact and the practical application of pH control to water softening operations without discoloring or otherwise destroying the usefulness of the softened water are features which appear to be new in the present invention.

One of the electrode assemblies which is indicated generally at 32 or 33 is shown more in detail in Fig. 2. Here the pipe I2 is shown entering and leaving the electrode assembly 32. In practice it may be preferable to bleed off a small quantity of the test iiuid or ellluent (the softened water or brine elluent to be measured) and the numeral I2A may denote this pipe. 'I'he test fluid may be fed back to the main body of uid without injury because no discoloring or harmful substance has been added; but inasmuch as the amount bled off will be negligible it may simply be discarded after passing the electrode assembly. If the bleeder pipe I2A is used, one of the pipes I2 in Fig. 2 may be discarded, the other being adequate for discharge from the electrode assembly casing.

The electrode assembly 32 comprises the antimony measuring electrode or half-cell 32A, having its tip exposed beyond the end of a hard rubber ller or holder 32B. 'I'he calomel reference electrode or half-cell comprises an outer glass tube 32D and a glass cup 32E which slips down into the tube until it brings up against a ground glass joint 32F. The tube and cup are filled to a level higher than the level of the test fluid 32G outside with a suitable fluid 32J such as a saturated potassium chloride (KCl) solution. Held within the tube 32D by a stopper 32H is an inner glass tube 32K carrying a brass conductor 40 connected to a platinum electrode 32M. A glass seal 32N is provided within the tube 32K. The tube 32K has an opening 32P on the side below the seal 32N to permit the solution (KCl) to enter. In the bulbous bottom of the tube 32K there is placed a body of material 32R consisting of mercury (Hg) with a. suspension or emulsion of calomel or mercurous chloride (HgzClz). The material 32H contacts with the platinum electrode 32M and the solution 32J contacts with both. The solution also seeps through the ground glass joint 32F of the outer tube to keep the joint moist, though without appreciable leakage, and forms an electrical circuit or bridge from the calomel-mercury emulsion to the test iluid.

It is understood that electrolysis is the `basis of action of pHvindicators but applicant makes no claim to the theory of action of pH indicators. One type has been illustrated but it is to be understood that there may be many other types.

The pH indicator is provided with adjustable contacts 30a and 33h, the iirst being for lowpH value and the second for high pH value. These contacts 30a and 30h, in conjunction with the needle of the pH indicator, control a master switch or relay SI, the switch beingmoved and held in either of two opposite directions after actuation by one or the other of the4 solenoid coils 30e and 30d associated with the contacts 30a and 30h respectively.

The switch blade of switch SI controls four sets of contacts, two sets on each side. One set, a,

supplies current from the line L to the branches 34, 35, 36, 31 serving the switch S3 and the solenoid valves A and B. Another set, b, on the.

same side through conductors 33b-and 43h supplies current from the electrode assembly 33 to the coil 3| of the pH indicator. On the other side of the switch one set of contacts. c, supplies current from the line L through the wire 33 to the switch S1 controlling the motor M2. The other set on the same side, d, through the conductors 38a and 43d supplies current from the electrode assembly 32 in the soft water pipe to the coil 3| of the pH indicator. The conductors 33 and 40 of the electrode assembly shown in Fig. 2 connect with the conductors 38a or 38h and 40d or 40b for the electrode assemblies 32 or 33 respectively of Fig. 1.

Switch S3 is connected with the solenoid coils of valve C by wire 4I.

Switch S6 is connected to the solenoid coil oi.' valve D by the wire 44. u

While the contacts of the pH indicator are shown as being directly connected in the main power line for operating switch SI it will be understood that suitable relays or other devices may be interposed if necessary or desirable in the usual manner of building'up power for operating devices. The same applies to the valves and other operating parts, the present disclosure not being intended to show every detail of a commercial installation but merely enough to enable one sllled in the art to successfully use the invention.

'I'he operation of the apparatus described may be as follows:

When the zeolite in the softener is exhausted the pH value' of the eiiluent reaches its lowest point and the needle of the pH indicator makes contact with the terminal 30a. 'Ihis causes en ergization of the coil 30e of the switch Sl to move the switch to the left to start automatic regeneration of the softener.

In more detail, the operation begins with the closing of the pair of contacts a and b connected by wires or conductors 34, 35, 36 and 31 with switch S3 of the brine recovery tank and the solenoid coils of valves A and B in the soft water line I2 and the hard water supply line II respectively. Valves A and B are closed to cause discontinuance of the softening operation. At

the same time contact ismade through switch Sbthe iioat being in uppermost position, to the solenoid coil oi' thewaste valve C to open the valve.

'I'he contents of the brine recovery tank I4 are 3 permitted. by reason of the release of back presv sure on the check valve I3,to ow through the pipe I 3 into the softener and out the waste pipe 2l. The contents oi the brine recovery tank include the new brine from .the previous brining operation, the water required to rinse out the brine, and the water required 'to complete the iilling of the tank.

When the level in the brine recovery tank drops to a given level the iioat causes the switch S3 to be opened.` 'I'his de-energizes the solenoid coil of waste valve C and closes the waste pipe. It also closes the switch S4'. Since the other switch S3 for the motor MI is closed, the iloat in ,the brine measuring tank being in its uppermost `position, the motor MI and its pump PI are started into operation to pump brine from the brine measuring tank 23 through pipes 24, 22 and I5 into the top oi' the zeolite softener tank I3. 'I'he brineiiows down through the softener and out the pipes I3 and I3 (the valve C to the waste pipe being closed) and up into the brinerecovery tank I4.

When the level in the brine measuring tank 23 reaches a predetermined lower level the iloat of switch SI opens it contacts and stops the operation of the motor MI and pump PI. At the same time it closes the contacts of switch S3 and applies current from the line L to the solenoid coil oi.' the valve D in the hard water by-pass pipe 25 to permit water to flow from the hard'water supply pipe II into the topof the softener to rinse out the brine. This is called the brine rinsing operation. The emuent .of the brine rinse passes out the pipe I3 and iiows through pipe I3 up into the brine recovery tank I4 with the brine which has just passed through.

When the brine rinse reaches its highest pH value it causes the pH indicator, through the electrode assembly 33 in the pipe I3. to be deflected to the right to engage the contact 33h. This causes energization oi' the solenoid coil 33d oi' the switch SI to move the switch blade to This de-energizes the solenoid coils ofthe valves A and B allowing the valves to open same time deenergizes the solenoid coil oi' valve D allowing the valve to close. Hard water may now flow into the soitenerthrough the pipe II and may flow out as soft water through the pipe I2 or may now up into the b through the pipe I3. It does theV tank is full, when the oat causes close and shut on' the i'low.

latter until the the valve I1 to It opens switch S4 so the pump PI cannot be operated until thetank I4'is again emptied.

The blade of switch Silalso closes the power circuit from line L to the motor M2. the switch vS'l having already been closed by the i'allv of its associated float in the brine measuring tank,

pump P2 into operathe right.-

and at the e recovery tank This also closes ,l switch S3 to condition it for the next operation.

brine from the brine ing tank opens the contacts of switchSG. At the same time the contacts of switch S5 are closed, 15

thus conditioning this switch for the next operation.

The softening apparatus has now been put back into normal operation and will so continue until the water delivered again drops to the low pH value as detected by the pH electrode assembly 32 required to re-cycle the apparatus.

It is to be noted that the contacts b and d for the electrode assemblies 32 and 33 are placed in such position relative to the blade of switch SI that each movement of the switch blade conditions one electrode assembly for control of the pH indicator and renders the other electrode assembly ineffective. However, the pH indicator as described up to this point, is at all times subject to the influence of current from one or the other of the electrode assemblies.

Instead of utilizing the higher pH value of the brine rinse to return the apparatus to normal operation, this may be accomplished by a oat controlled switch associated with the brine recovery tank I4. The switch will be closed when the tank is full and opened when the tank is empty. The parts controlled by this switch may be exactly the same as those controlled through the high reading contact 33h. That is, the right coil 30d of switch Si will be energized when the float controlled switch is closed subsequently to the regenerating operation.

In some instances it may be desired to operate without the pH indicator being connected into the circuit. In this case the switch SI may be operated by hand and when once operated at the start or finish of the regeneration the rest of the cycle is automatically completed.

The term "zeolite" is used in this application in the same sense that it is used in the commercial eld, to refer to base exchange materials generally. The term regeneration is also used in its common commercial sense to refer to regeneration of a zeolite by a regenerating base exchange medium. And while the base exchange medium mentioned herein by way of example is a brine of sodium chloride, because this is now most commonly used, it is to be understood that sodium chloride brine is not the only brine which may be used and also that brine is not the only regenerating medium which may be used, the medium used in any case beingthe one best adapted to serve the base exchange material employed for its intended purposes.

While one embodiment of the invention has been described in detailto furnish a concrete conception of the principles of the invention it will be understood that the invention may be variously embodied within the limits of the prior art and the scope of the subjoined claims.

I claim:

1. The method of controlling the operation of a zeolite water softener which comprises, determining the pH value of the eiiiuent from the softener and controlling the cycle of operation of the softener in accordance with the pH value thus determined.

2. The method of controlling the operation of a zeolite water softener which comprises, continuously registering the pH value of the effluent from the softener on a pH indicator, and automatically, controlling the cycle of operation of sid softener by and in accordance with limiting values registered by said indicator.

3. The method of controlling the operation of a zeolite water softener which comprises, continuously registering the pH value of the eiliuent from the softener on a pH indicator, and controlling the cycle of operation of said softener by and in accordance with limiting values registered by said indicator.

4. The method of controlling the operation of a zeolite water softener which comprises, stopping the softening operation when the pH value of the effluent, reaches a lower limit, regenerating the zeolite and subsequently restarting the softening operation in conformity with a control indication given after the completion of the regenerating operation.

5. 'I'he method of controlling thel operation of a zeolite water softener which comprises, stopping the softening operation when the pH value of the soft water eiiluent reaches a lower limit, regenerating the zeolite with a brine solution, rinsing the brine from the zeolite, and restarting the softening operation when the pI-I value f the brine rinse reaches a higher limit.

6. The method of controlling the operation of a zeolite water softener which comprises automatically stopping the softening operation by and in accordance with a predetermined lower limit of pH value of the soft water effluent as registered on a pH indicator, regenerating the zeolite as an effect produced by said indicator, rinsing the brine from said zeolite as a controlled result of the brining operation, and restarting the softening operation automatically by and inl accordance with a predetermined limit of the pH value of the brine rinse as registered on a pH indicator.

7. Apparatus for softening water, comprising in combination, a zeolite water softening device, means for supplying hard water to said device and withdrawing soft water eiliuent therefrom, and means responsive to the pH values of said eiliuent for controlling the operation of said apparatus.

8. Apparatus for softening water, comprising in combination, a zeolite water softening device, means for supplying hard water to said device and withdrawing soft water effluent therefrom, and means including a pH indicator and a connection therefrom to said soft water effluent for controlling the operation of said apparatus in accordance with the pH values of said soft water effluent.

9. Water softening apparatus comprising in combination, a zeolite water softening device, a pipe for supplying hard water to said device and a pipe for withdrawing soft water effluent from said device, solenoid controlled valves for said pipes, a brine recovery tank, means for supplying brine from said brine recovery tank to said softening device, a brine measuring tank, means including a motor and a pump for supplying brine from saidbrine measuring tank to said softening device and thence to said brine recovery tank, a brine storage tank, means including a second motor and pump for supplying brine from said storage tank to said measuring tank, a waste pipe from said softening device and a solenoid controlled valve for the waste pipe, a hard water by-pass pipe and a solenoid controlled valve for the by-pass pipe, a pH indicator, a pH electrode assembly in said soft water pipe for actuating said pH indicator in accordance with the pH values of the soft water, an adjustable limit contact on said pH indicator adapted to be contacted when the zeolite of the softener is exhausted as indicated by the electrode assembly in the soft water line, a master switch controlled by said pH indicator, said switch being actuated when the pH indicator registers exhaustion of the zeclite to close the valves in said soft water and hard water pipes and to open the valve in said waste pipe, the brine from said brine recovery tank thereupon owing through said softening device to regenerate the zeolite therein, a iioat controlled switch and valve associated with said brine recovery tank, the closing of said switch by the drop of the oat in the brine recovery tank closing the valve in said waste pipe and starting said first motor and pump to empty the brine from the brine measuring tank into said brine recovery' tank, a float controlled switch associated with said brine measuring tank operative when the float drops to stop the operation of said first motor and pump, and a second oat controlled switch operative when the float in the brine measuring tank drops for opening the valve in said hard water by-pass pipe to permit Water to ow through the zeolite to remove excess brine therefrom and carry it to the brine recovery tank, means associated with the rinse eiuent handling means of said device for reversing the position of said master switch after the zeolite has been regenerated and rinsed free of brine, the reversal of said master switch causing the valves in the soft water and hard water lines to be opened and -the second motor and pump to be started to ll said brine measuring tank from said brine storage tank, and a sec'ond float controlled switch associated with said brine measuring tank for stopping the operation of said second motor and pump when the tank is full, the lling of said tank also causing the closing of the valve in the hard water by-pass pipe.

10. The method of controlling the operation of a zeolite Water softener which comprises, continuously registering the pH value of an eiiluent from the softener on a. DH indicator, and controlling a plurality of distinct phases of action of said softener by and in accordance with predetermined pH values registered by said indicator.

11. Apparatus for softening water comprising in combination, a zeolite water softening device of operating phases of the softener automatically and in accordance with different pH values of the eluent from said softener.

12. The method of controlling the operation of a zeolite water softener which comprises, `continuously registering the pH value of an eiiluent from the softener on a constant-registering pH indicator of the electrolytic type Without requiring the addition of color indicating substances or other contamination to the water, and controlling a plurality of distinct phases of action of said softener automatically by and in accordance with predetermined pH values registered by said indicator.

RICHARD E. WAGNER. 

